Conversion assemblage adaptable for use in combination with a surface modifying apparatus and method thereof

ABSTRACT

The disclosure is directed to a conversion assemblage adapted for use in converting a surface modifying mechanism, such as a pole sander, having an attaching member. The surface modifying assemblage and method facilitate converting the pole sander with anyone of several different surface treating assemblages in an easy and reliable manner as well as provides for enhanced surface modifying efficiencies and improvements.

BACKGROUND

The present description is directed to providing a surface modifying assemblage for use in combination with a surface modifying apparatus. More particularly, the present description is directed to providing a surface modifying assemblage and method that facilitates converting a surface modifying apparatus, such as a pole sander, with anyone of several different surface treating assemblages in an easy and reliable manner.

Surface modifying devices, such as hand held tools, have been used for working or modifying a wide variety of surfaces. For example, when fabricating a structure, such as a wall or ceiling, it is sometimes necessary to utilize a sanding device to smooth the surface of the structure. For example, interior walls of office buildings and houses typically use drywall panels. The drywall panels may be attached to wood or metal frames to form interior walls and ceilings. Joints or seams are formed along edges where the different dry wall panels are juxtaposed to each other. Typically, the seams are covered with a compound and smoothed. This is to give the appearance that the seams do not exist and provide a wall that is otherwise seamless, smooth, and flat.

Treating compounds are applied wet to the drywall to fill in the seams and any gaps between the drywall panels. Once dry, the compounds are typically sanded smooth. One known type of hand held tool assembly for sanding includes a pole sanding tool that comprises a generally rectangular sanding attachment head attached to a handle or pole through a pivoting structure. Pole sander attachment heads have a fixed size. An elongate sheet of sanding paper for treating the surface is attached to the fixed sized attachment head and usually some effort is required to properly secure the sanding paper to the attachment head due to attaching mechanisms of the latter. Because different sanding grades are used to sand, repeated effort is required to replace these sanding papers during a typical drywall finishing operation.

Moreover, sanding steps generally are repeated several times until seams and gaps appear unnoticeable. The requirements for a smooth and flat finish are quite demanding. Even minor blemishes are usually found to be unacceptable. As such, repetitions of sanding tend to add to user fatigue as well as material and labor costs. Accordingly, the process is labor intensive and time consuming. As a consequence, there is an interest in making the sanding operations more efficient from a labor and time standpoint and less fatiguing in practice.

Moreover, some pole sanding tools when manipulated have a tendency for their attachment head to flip onto its elongate side and thereby gouge or otherwise damage the surface being treated. Clearly, the damage caused by flipping of pole sanders requires additional expenditures of time and labor.

In addition, some drywall finishing operations may require other surface modifying applications besides sanding, such as, cleaning, painting, and the like. Accordingly, costs for treating drywall increases due to different specialty tools and surface modifying assemblages being required before a wall may be wallpapered or painted. As a consequence, there is an interest in making such operations less expensive and time consuming. As such there is continuing interest in seeking improvements in addressing the foregoing issues in an expeditious and cost effective manner.

SUMMARY

The present description is directed to a conversion assemblage for use in converting a surface modifying mechanism having an attaching member. The conversion assemblage comprises: a substantially rigid body assembly including first and second major surfaces opposing each other, the first major surface is attachable to a supporting member of a surface modifying mechanism; the second surface is attachable to a surface modifying member.

The present description is directed to a conversion assemblage for converting a pole sander apparatus having a pivotally connected supporting member. The assemblage comprises: a substantially rigid body assembly including first and second major surfaces opposing each other, the first major surface is adapted for receiving the supporting member, and the second major surface is attachable to a surface modifying member.

The present description is directed to a method of converting a surface modifying mechanism having an attaching member. The method comprises: providing a conversion assemblage including a body assembly made of a relatively stiff material configured with at least a first major surface and a second major surface opposing the first major surface; an attaching layer connected to the second major surface; and a surface modifying layer releasably connected to the attaching layer; and securing the surface treating assemblage to the attaching member.

One aspect of the present description is for facilitating the conversion of a surface modifying mechanism, such as a pole sander, with one or more conversion assemblages that enhance versatility of the pole sander through use of several different kinds of surface modifying articles.

Another aspect of the present description is for accomplishing the above in a manner that improves surface modifying efficiency and ease of worker manipulation of the surface modifying mechanism.

Another aspect of the present description is to accomplish the above by improving the efficiency of surface modification, through the use of relatively large and lightweight surface modifying assemblies in a manner that reduces user fatigue.

Another aspect of the present description is to minimize damage to surfaces, such as gouging or otherwise marring the surface finishes, when using surface modifying tools, such as pole sanders and other similar devices.

Another aspect of the present description is to accomplish the above by minimizing flipping of a pole sander during use. Another aspect of the present description is to accomplish the above by minimizing the tearing of surface modifying sheets, such as abrasive sanding sheets during surface treating.

Another aspect of the present description is to accomplish the above in a manner that is cost effective to manufacture, assemble, and use.

The aspects described herein are merely a few of the several that can be achieved by using the present description. The foregoing descriptions thereof do not suggest that the present description must only be utilized in a specific manner to attain the foregoing aspects.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one exemplary embodiment of a conversion assemblage being mounted on a pole sander attachment;

FIG. 2 is an exploded perspective view of the conversion assemblage of FIG. 1.

FIG. 3 is a perspective view of another exemplary embodiment of a conversion assemblage being mounted on a pole sander attachment;

FIG. 4 is an exploded perspective view of the conversion assemblage of FIG. 3.

DETAILED DESCRIPTION

The present description is directed to a conversion assemblage and method that facilitates converting a surface modifying apparatus or tool so as to make the latter more versatile, especially in a manner for improving surface modifying efficiency as well as minimizing damage to the surface being treated and any surface modifying article being utilized.

The words “an,” and “the” are used interchangeably with “at least one” to mean one or more of the elements being described. By using words of orientation, such as “top,” “bottom,” “overlying,” “front,” and “back” and the like for the location of various elements in the disclosed articles, we refer to the relative position of an element with respect to a horizontally-disposed body portion.

FIGS. 1 and 2 illustrate one exemplary embodiment of a surface modifying mechanism 10, such as a pole sanding device 10 for treating a generally planar working surface, such as a wall, ceiling or other similar structures. While one embodiment of a pole sander device is described and illustrated, it will be appreciated that other versions may be used, such as those that include wing nut and attaching clamps. Also, while a pole sanding device 10 is described, the present description envisions that a variety of hand tools may be used within the spirit and scope of the present description. In addition, while abrading a surface as by sanding is described hereinafter, the present description envisions other surface treating methods, such as cleaning, painting and the like. While a pole sanding hand tool is described as being non-motorized, it will be appreciated that the hand tool may be motorized and/or provided with additional devices, such as a vacuum device and the like.

FIGS. 1 & 2 illustrate one exemplary embodiment of a conversion assemblage 12 of present description that is adapted for converting the pole sander device 10 having a supporting member 14 or attaching member 14. In the illustrated exemplary embodiment, the conversion assemblage 12 is adapted for use in conversion of a surface modifying mechanism 10, such as a manually powered pole sander device 10. Pole sanders are typically used to reach areas, such as drywall areas, that are beyond arms reach of a user.

In FIG. 1, the pole sander head 14 or attachment member 14 is to be coupled to an extension pole 16 or handle 16, a portion of which is illustrated. Pole sander devices that may be used in the exemplary embodiments are commercially available. The extension pole 16 is to be manually operated by a user interested in treating a wall surface (not shown). The pole sander head or attachment member 14 includes a pivoting or universal joint 18 mounted on a generally flat and elongated rectangular plate 20 having a bottom surface 21. The plate 20 may be made of a relatively rigid plastic or metal. The pivoting or universal joint 18 on the top surface of the plate 20, includes a sleeve 24 rotatably mounted on a pin 26 extending between two bearings 28 for rotation parallel to the longitudinal axis of the plate 20. A pole mounting fixture 30 is pivotally mounted to the sleeve 24 for rotation transverse to the longitudinal axis of the plate 20 about a pin 32. The pole mounting fixture 30 has an internal threaded fitting (not shown) for receiving an extension pole 16 in a known manner. It will be understood, however, that the scope of the present application extends to other forms of attaching a pole to the plate 20 which permit the pole to pivot longitudinally and laterally with respect to the plate 20, e.g., a ball and socket joint.

In some sanding situations, the bottom surface 21 of the pole sander head 14 may be without any material added thereto. In the illustrated embodiment, the pole sander head 14 may have a sponge 36, such as made of Neoprene™ or foam pad 36 secured to the bottom of the plate 20. Typically, with most pole sanders an abrasive sanding paper (not shown) is added to conform to the size and shape of the sponge 36. During usage of known sanding pole sanders, as noted above, sanding papers tend to become easily damaged, such as when striking edges or the like. In addition, the relatively small size of the sponge and thereby the surface area being sanded tends to limit the efficiency of the sanding operation. In addition, there is very little versatility with known pole sanders since they are primarily used as sanding devices and are not generally capable of performing other surface treating applications.

According to the present description, conversion of a pole sander head 14 to accommodate the conversion assemblage 12 may commence with adding an attaching member 42. This may be done prior to adding the conversion assemblage 12 to the pole sander device 10. The attaching member 42 may be shaped and sized to generally match the size and shape of the pole sander head 14. The attaching member 42 may be provided with opposing first and second major surfaces 43, 44, respectively. The major surface 43 may be attached to the bottom surface 21 permanently as by an adhesive. Alternatively, the major surface 43 may be releasably attached to the bottom surface 21 by a pressure sensitive adhesive. While not illustrated, the present description envisions that the surfaces 21 and 43 may be joined by a releasable mechanical fastening device. In this exemplary embodiment, the attaching member 42 may be at least one strip that encompasses the surface area of the sponge 36. The major surface 44 may include one or more strips of a hook and loop system element 46, such as hook members 46.

The conversion assemblage 12 in the illustrated exemplary embodiment is defined as a relatively rigid and lightweight body assembly 50. The body assembly 50 defines a first and second major surface 52, 54, respectively. It will be appreciated that the body assembly 50 may have a variety of shapes and sizes. To facilitate the sanding operation, the second major surface 54 has an area that is significantly larger than the area of the attachment head 14. In the exemplary embodiment, the body assembly 50 has a generally rectangular shape that is significantly larger than the attachment head, such as in the order of about 50% to about 150% larger. Of course, the present description is not limited to any such increases in size. A recess 56 in the body assembly 50 that, in part, defines the first major surface is sized to accommodate therein the pole sander head 14 including the attaching member 42, much in the manner that is illustrated in the drawings. The recess may be sized and shaped to receive the supporting member so that its center of gravity is close to a center of gravity of the body assembly, whereby flipping over of the body assembly during use is inhibited.

The body assembly 50 is made of a molded lightweight, low density, relatively strong, and stiff thermoplastic material. The rigidity is useful from a standpoint of enabling a user to apply pressure more uniformly to a surface modifying article being carried thereby. A rigid backing for abrasives tends to make for a smoother finish provided by the abrasives. The low density and generally lightweight construction allows the molded body assembly 50 to be relatively easily handled by a user. This tends to lower fatigue during use. In addition, the rigid and lightweight construction enables formation of relatively larger surface abrading areas without drawbacks of additional weight. Also, the low density and relatively rigid construction enables formation of a relatively hard edge, compared to conventional pole sander attachment head sponges. This is particularly useful for abrading in corners, such as between ceilings and wall surfaces. The relatively hard edge tends to lessen the likelihood of abrasive surfaces, such as paper type abrasives articles, being torn or otherwise damaged. Also, the material of the present description is intended to be reusable, thereby enhancing overall versatility of the conversion assembly, since many different surface modifying articles may be added thereto. Accordingly, the body assembly 50 may dispense with the need for requiring different tools that carried different surface modifying articles.

In the exemplary embodiment, the present description envisions use of a molded polystyrene foam material that has a relatively low density. For example, the density may be in the order of about 2.50 pounds/ft.³ to about 6.00 pounds/ft.³. The molded polystyrene foam may be open or closed cell although in the exemplary embodiment it is a closed cell type. Other suitable materials may be used, such as but not limited to polymeric foams, such as, polystyrenes, polyurethanes, polyolefins, polyesters, and combinations thereof.

Referring back to the recess 56, it includes a plurality of pads 60 having exposed loop type fastening elements (not shown) that are adapted to releasably and engage and attach to the hook elements on the attaching member 42. While a plurality of pads 60 are disclosed, a single pad may be used instead. In addition, the present description envisions use of other releasable attachment mechanisms including a smooth surface that could cooperate with a pressure sensitive adhesive attaching member.

Connected to the second major surface is an attachment layer 70 for use in releasable connection to a surface modifying member 80. In the exemplary embodiment, the attachment layer 70 may be a pad 72 having openings 73 that reduce weight and have projecting hooks 74 on a bottom major surface thereof, whereas the upper major surface may have a pressure sensitive adhesive layer 76 for releasable attachment to the second major surface 54. The hooks 74 are adapted to releasably engage the surface modifying member 80. In the exemplary embodiment, the surface modifying member 80 may be a foam backed abrasive article 80. The foam backed abrasive article 80 includes a foam back attachment layer 82 that has a working surface 84 which includes abrasive particles 84 coated thereto. The foam attachment layer 82 may be made of a relatively thin and lightweight material. The abrasives may be made of any suitable material. Because of the versatility of the present description, different abrasive grades for sanding may be used, such as 100, 120 and 150. These examples are merely illustrative and are not considered limiting. In one exemplary embodiment, the foam back attachment layer 82 may be a lightweight polyurethane, such as a molded open cell polyurethane. In other embodiments, synthetic polymer foams, such as, polyurethanes, Neoprene™, styrenebutadiene rubber, polyethylenes, acrylic foams, and combinations thereof may be used. The thickness of the foam back attachment layer 82 may be in the order of about 1-5 mils. In one exemplary embodiment, such a foam backed attachment layer may be commercially available from 3M Company, St. Paul, Minn. under the trade name Sandblaster™. While a foam backed abrasive article may be used, other coupling mechanisms for coupling a surface modifying abrasive mechanisms may be used. For example, the present description envisions all kinds of releasable attachment mechanisms, including, but not limited, to a wide variety of hook and loop fastening elements or mechanisms or the like. Some fastening elements include solid protrusions including a stem and an expanded region or head that may take a variety of shapes. Exemplary patents describing this latter type of a fastener include: U.S. Pat. Nos. 3,192,589 and 5,097,570. Another type of fastening element including a multiplicity of intermeshing solid protrusions is described in U.S. Pat. No. 4,875,259. An example of a suitable hook and loop mechanism is commercially available from 3M Company, St. Paul, Minn. under the trade name designations Hookit™ and Hookit™ II. Other suitable configurations of hook and loop attachments are within the scope of the present disclosure. Also, any suitable adhesive system including any kind of pressure-sensitive adhesive may be used instead of the hook and loop arrangements.

Reference is now made to FIGS. 3 & 4 for illustrating another exemplary embodiment of the present description which is similar to FIGS. 1 & 2. Accordingly, similar structure is represented by similar reference numerals with the addition, however of the prefix “1”. Differences of this embodiment to the foregoing include the body assembly 150 may be a two-piece upper and lower 150 a and 150 b, respectively, construction made of suitable plastic, such as expanded polystyrene, polyethylene, ABS, and Neoprene™, and combination thereof. In addition, the foam backed surface modifying article 180 may be provided with openings 185 therein for reducing weight of the overall conversion assemblage.

This present description may take on various modifications and alterations without departing from the spirit and scope. Accordingly, this present description is not limited to the above-described embodiments, but is to be controlled by limitations set forth in the following claims and any equivalents thereof. This present description also may be suitably practiced in the absence of any element not specifically disclosed herein. All patents and publications noted above, including any in the Background section are incorporated by reference into this document in total. 

1. A conversion assemblage adapted for use in converting a surface modifying mechanism having an attaching member, the conversion assemblage comprising: a substantially rigid body assembly including first and second major surfaces opposing each other, the first major surface is attachable to a supporting member of a surface modifying mechanism; the second surface is attachable to a surface modifying member.
 2. A conversion assemblage adapted for converting a pole sander apparatus having a pivotally connected supporting member, the assemblage comprising: a substantially rigid body assembly including first and second major surfaces opposing each other, the first major surface is adapted for receiving the supporting member, and the second major surface is attachable to a surface modifying member.
 3. The conversion assemblage of claim 2, the rigid body assembly is a relatively lightweight material.
 4. The conversion assemblage of claim 2, wherein the rigid body assembly includes a recess therein for removably receiving therein at least a portion of the supporting member.
 5. The conversion assemblage of claim 2, further including a first attachment assemblage on the body assembly that includes the first major surface, and a second attachment assemblage on the body assembly that includes the second major surface.
 6. The conversion assemblage of claim 5, wherein the first attachment assemblage includes a mechanical attachment system.
 7. The conversion assemblage of claim 6, wherein the mechanical attachment system includes at least one of a hook and loop fastener element.
 8. The conversion assemblage of claim 5, wherein the second attachment assemblage includes a mechanical attachment system.
 9. The conversion assemblage of claim 8, wherein the mechanical attachment system includes at least one of a hook and loop fastener element.
 10. The conversion assemblage of claim 5, wherein the second attachment assemblage includes a pressure sensitive adhesive assembly.
 11. The conversion assemblage of claim 2, wherein the body assembly is made of a material from a group consisting of: polymeric foams, polystyrene foams, polyurethane foams, polyolefin foams, polyester foams, acrylic foams, and combinations thereof.
 12. The conversion assemblage of claim 4, wherein the recess is sized and shaped to receive the supporting member so that its center of gravity is close to a center of gravity of the body assembly, whereby flipping over of the body assembly during use is inhibited.
 13. The conversion assemblage of claim 2, wherein the body assembly has a peripheral edge dimension that exceeds a peripheral edge dimension of a supporting member.
 14. The conversion assemblage of claim 2, further including a surface modifying article having a first surface attached to the second major surface of the body assembly, wherein the surface modifying article has an abrasive material on a second major surface thereof.
 15. The conversion assemblage of claim 14, wherein the surface modifying article includes a foam backed element defining a first major surface thereof, and an abrasive article on a second major surface of the foam backed.
 16. The conversion assemblage of claim 2, wherein the body assembly has a density in a range of about 2.50 pounds/ft.³ to about 6.00 pounds/ft.³.
 17. A method adapted for utilizing a conversion assemblage for converting a surface modifying mechanism having a supporting member, the method comprising: providing a conversion assemblage including a substantially rigid body assembly including first and second major surfaces opposing each other, the first major surface is attachable to the supporting member; and the second major surface is attachable to a surface modifying member; and securing an attaching member to the supporting member for attaching to the first major surface.
 18. The method of claim 17, further comprising attaching the first major surface to the attaching member secured on the supporting member.
 19. The method of claim 17, wherein the providing of the substantially rigid body assembly also includes providing a lightweight material.
 20. The method of claim 19, wherein the providing includes selecting at least one of a material from a group consisting of: polymeric foams, polystyrene foams, polyurethane foams, polyolefin foams, polyester foams, acrylic foams, and combinations thereof. 